SMART Digital S - DDE

24
SMART Digital S - DDE up to 15 l/h Installation and operating instructions GRUNDFOS INSTRUCTIONS Further languages http://net.grundfos.com/qr/i/95725839

Transcript of SMART Digital S - DDE

Page 1: SMART Digital S - DDE

SMART Digital S - DDEup to 15 l/h

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

Further languages

http://net.grundfos.com/qr/i/95725839

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English (GB) Installation and operating instructions

Original installation and operating instructions

CONTENTSPage

1. Safety instructionsThese installation and operating instructions contain general instructions that must be observed during installation, operation and maintenance of the pump. It must therefore be read by the installation engineer and the relevant qualified operator prior to installation and start-up, and must be available at the installation location at all times.

1.1 Symbols used in this document

1.2 Qualification and training of personnel

The personnel responsible for the installation, operation and service must be appropriately qualified for these tasks. Areas of responsibility, levels of authority and the supervision of the personnel must be precisely defined by the operator. If necessary, the personnel must be trained appropriately.

Risks of not observing the safety instructions

Non-observance of the safety instructions may have dangerous consequences for the personnel, the environment and the pump and may result in the loss of any claims for damages.It may lead to the following hazards:• Personal injury from exposure to electrical,

mechanical and chemical influences.• Damage to the environment and personal injury

from leakage of harmful substances.

1. Safety instructions 21.1 Symbols used in this document 21.2 Qualification and training of personnel 21.3 Safety instructions for the operator/user 31.4 Safety of the system in the event of a

failure in the dosing pump 31.5 Dosing chemicals 31.6 Diaphragm breakage 42. General information 42.1 Applications 42.2 Improper operating methods 42.3 Symbols on the pump 52.4 Nameplate 52.5 Type key 62.6 Product overview 73. Technical data / Dimensions 73.1 Technical data 73.2 Technical data for CIP (Clean-In-Place)

applications 93.3 Dimensions 94. Assembly and installation 104.1 Pump assembly 104.1.1 Requirements 104.1.2 Align and install mounting plate 104.1.3 Engage pump in mounting plate 104.2 Hydraulic connection 104.3 Electrical connection 115. Startup 135.1 General notes 135.2 Check before commissioning 135.3 Start and deaerate the pump 136. Operation 136.1 Operating elements 136.2 Operation modes 146.2.1 Manual 146.2.2 Pulse 146.2.3 Change operation modes 146.3 Inputs/outputs 146.3.1 External stop 146.3.2 Empty and low-level signals 146.3.3 Relay outputs 156.3.4 Change settings 157. Service 167.1 Regular maintenance 167.2 Cleaning 167.3 Perform service 167.3.1 Dosing head overview 167.3.2 Dismantling the diaphragm and valves 177.3.3 Reassembling the diaphragm and valves 17

7.4 Diaphragm breakage 187.4.1 Dismantling in case of diaphragm

breakage18

7.4.2 Dosing liquid in the pump housing 187.5 Repairs 198. Faults 198.1 Indication of faults 198.2 List of faults 209. Disposal 20

WarningPrior to installation, read these installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice.

WarningIf these safety instructions are not observed, it may result in personal injury.

CautionIf these safety instructions are not observed, it may result in malfunction or damage to the equipment.

Note Notes or instructions that make the job easier and ensure safe operation.

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1.3 Safety instructions for the operator/user

The safety instructions described in these instructions, existing national regulations on health protection, environmental protection and for accident prevention and any internal working, operating and safety regulations of the operator must be observed.Information attached to the pump must be observed.Leakages of dangerous substances must be disposed of in a way that is not harmful to the personnel or the environment.Damage caused by electrical energy must be prevented, see the regulations of the local electricity supply company.

Only original accessories and original spare parts should be used. Using other parts can result in exemption from liability for any resulting consequences.

1.4 Safety of the system in the event of a failure in the dosing pump

The dosing pump was designed according to the latest technologies and is carefully manufactured and tested.If it fails regardless of this, the safety of the overall system must be ensured. Use the relevant monitoring and control functions for this.

1.5 Dosing chemicals

Caution

Before starting work on the pump, the pump must be disconnected from the power supply. The system must be pressureless!

NoteThe mains plug is the separator separating the pump from the mains.

Caution

Make sure that any chemicals that are released from the pump or any damaged lines do not cause damage to system parts and buildings.The installation of leak monitoring solutions and drip trays is recommended.

WarningBefore switching the supply voltage back on, the dosing lines must be connected in such a way that any chemicals in the dosing head cannot spray out and put people at risk.The dosing medium is pressurised and can be harmful to health and the environment.

WarningWhen working with chemicals, the accident prevention regulations applicable at the installation site should be applied (e.g. wearing protective clothing).Observe the chemical manufacturer's safety data sheets and safety instructions when handling chemicals!

CautionA deaeration hose, which is routed into a container, e.g. a drip tray, must be connected to the deaeration valve.

Caution

The dosing medium must be in liquid aggregate state!Observe the freezing and boiling points of the dosing medium!

Caution

The resistance of the parts that come into contact with the dosing medium, such as the dosing head, valve ball, gaskets and lines, depends on the medium, media temperature and operating pressure.Ensure that parts in contact with the dosing medium are resistant to the dosing medium under operating conditions, see data booklet!Should you have any questions regarding the material resistance and suitability of the pump for specific dosing media, please contact Grundfos.

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1.6 Diaphragm breakage

If the diaphragm leaks or is broken, dosing liquid escapes from the drain opening (fig. 10, pos. 11) on the dosing head. Observe section 7.4 Diaphragm breakage.

To avoid any danger resulting from diaphragm breakage, observe the following:• Perform regular maintenance. See section

7.1 Regular maintenance.• Never operate the pump with blocked or soiled

drain opening.– If the drain opening is blocked or soiled,

proceed as described in section 7.4.1 Dismantling in case of diaphragm breakage.

• Never attach a hose to the drain opening. If a hose is attached to the drain opening, it is impossible to recognise escaping dosing liquid.

• Take suitable precautions to prevent harm to health and damage to property from escaping dosing liquid.

• Never operate the pump with damaged or loose dosing head screws.

2. General informationThe DDE dosing pump is a self-priming diaphragm pump. It consists of a housing with stepper motor and electronics and a dosing head with diaphragm and valves.Excellent dosing features of the pump:• Optimal intake even with degassing media, as

the pump always works at full suction stroke volume.

• Continuous dosing, as the medium is sucked up with a short suction stroke, regardless of the current dosing flow, and dosed with the longest possible dosing stroke.

2.1 Applications

The pump is suitable for liquid, non-abrasive, non-flammable and non-combustible media strictly in accordance with the instructions in these installation and operating instructions.

Areas of application

• Drinking water treatment• Wastewater treatment• Swimming pool water treatment• Boiler water treatment• CIP (Clean-In-Place) Observe section

3.2 Technical data for CIP (Clean-In-Place) applications.

• Cooling water treatment• Process water treatment• Wash plants• Chemical industry• Ultrafiltration processes and reverse osmosis• Irrigation• Paper and pulp industry• Food and beverage industries.

2.2 Improper operating methods

The operational safety of the pump is only guaranteed if it is used in accordance with section 2.1 Applications.

WarningDanger of explosion, if dosing liquid has entered the pump housing!Operation with damaged diaphragm can lead to dosing liquid entering the pump housing.In case of diaphragm breakage, immediately separate the pump from the power supply!Make sure the pump cannot be put back into operation by accident!Dismantle the dosing head without connecting the pump to the power supply and make sure no dosing liquid has entered the pump housing. Proceed as described in section 7.4.1 Dismantling in case of diaphragm breakage.

WarningOther applications or the operation of pumps in ambient and operating conditions, which are not approved, are considered improper and are not permitted. Grundfos cannot be held liable for any damage resulting from incorrect use.

WarningThe pump is NOT approved for operation in potentially explosive areas!

WarningA sunscreen is required for outdoor installation!

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2.3 Symbols on the pump

2.4 Nameplate

Fig. 1 Nameplate

Symbol Description

Indication of universally dangerous spot.

In case of emergency and prior to all maintenance work and repairs, take the mains plug out of the mains supply!

The device complies with electrical safety class II.

Connection for deaeration hose at dosing head. If the deaeration hose is not correctly connected, danger will arise due to possible leakage of dosing liquid!

TM04

814

4 17

20

PQU

Type

Modelf

Pmax

Imax

9769

4877

Made in France

N20683

NEMA 4Xpsi

gphA l/hBar

W IP 65

1 2 3 4 5 6 7

8910

Pos. Description Pos. Description

1 Type designation 6 Enclosure class

2 Voltage 7 Mark of approval, CE mark, etc.

3 Frequency 8 Country of origin

4 Power consumption 9 Max. operating pressure

5 Max. dosing flow 10 Model

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2.5 Type key

The type key is used to identify the precise pump and is not used for configuration purposes.

* Including: 2 pump connections, foot valve, injection unit, 6 m PE discharge hose, 2 m PVC suction hose, 2 m PVC deaeration hose (4/6 mm).

Code Example DDE 6- 10 P- PP/ V/ C- X- 3 1 U2U2 F G

Pump type

Max. flow [l/h]

Max. pressure [bar]

BPPR

Control variantBasicB with pulse modeP with relay output

PPPVCPVSS

Dosing head materialPolypropylenePVC (polyvinyl chloride, only up to 10 bar)PVDF (polyvinylidene fluoride)Stainless steel DIN 1.4401

EVT

Gasket materialEPDMFKMPTFE

CSS

Valve ball materialCeramicStainless steel DIN 1.4401

XControl cube positionNo control cube

3Voltage1 x 100-240 V, 50/60 Hz

12

Valve typeStandardSpring-loaded (HV version)

U2U2U7U7AAVVXX

I001I002I003I004

Suction/discharge side connectionHose, 4/6 mm, 6/9 mm, 6/12 mm, 9/12 mmHose 0.17" x 1/4"; 1/4" x 3/8"; 3/8" x 1/2"Threaded Rp 1/4, female (stainless steel)Threaded 1/4 NPT, female (stainless steel)No connectionInstallation set*Hose, 4/6 mm (up to 7.5 l/h, 13 bar)Hose, 9/12 mm (up to 60 l/h, 9 bar)Hose, 0.17" x 1/4" (up to 7.5 l/h, 13 bar)Hose, 3/8" x 1/2" (up to 60 l/h, 10 bar)

FBGIEJL

Mains plugEUUSA, CanadaUKAustralia, New Zealand, TaiwanSwitzerlandJapanArgentina

GDesignGrundfos

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2.6 Product overview

Fig. 2 Overview

3. Technical data / Dimensions

3.1 Technical data

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17

Mains connection

Mechanical lock

Mounting plate

Drain opening incase of diaphragm

breakage

Connection,deaeration hose

Valve, discharge side

Deaeration valve(Section 5.3)

Valve, suction side

Signal inputs/outputs* (Section 4.3)

Keys* and status LED

Dosing head

* only control variant DDE-PR/P

Operating elements (Section 6.1)

Capacity adjustment knob

Data 6-10 15-4

Mechanical data

Turn-down ratio (setting range) [1:X] 1000 1000

Max. dosing capacity[l/h] 6.0 15.0

[gph] 1.5 4.0

Min. dosing capacity[l/h] 0.006 0.015

[gph] 0.0015 0.0040

Max. operating pressure[bar] 10 4

[psi] 150 60

Max. stroke frequency [strokes/min] 140 180

Stroke volume [ml] 0.81 1.58

Accuracy of repeatability [%] ± 5

Max. suction lift during operation1) [m] 6

Max. suction lift when priming with wet valves1) [m] 2 3

Min. pressure difference between suction and discharge side [bar] 1

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1) Data is based on measurements with water2) Maximum suction lift: 1 m, dosing capacity reduced (approx. 30 %)3) Length of suction line: 1.5 m, length of discharge line: 10 m (at max. viscosity)

Mechanical data

Max. inlet pressure, suction side [bar] 2

Max. viscosity with spring-loaded valves2) [mPas] (= cP) 600 500

Max. viscosity without spring-loaded valves2) [mPas](= cP) 50

Min. internal hose/pipe diameter suction/discharge side1), 3) [mm] 4 6

Min. internal hose/pipe diameter suction/discharge side (high viscosity)3) [mm] 9

Min./Max. liquid temperature [°C] -10/45

Min./Max. ambient temperature [°C] 0/45

Min./Max. storage temperature [°C] -20/70

Max. relative humidity (non-condensing) [%] 96

Max. altitude above sea level [m] 2000

Electrical data

Voltage [V] 100-240 V, - 10 %/+ 10 %, 50/60 Hz

Length of mains cable [m] 1.5

Max. inrush current for 2 ms (100 V) [A] 8

Max. inrush current for 2 ms (230 V) [A] 25

Max. power consumption P1 [W] 19

Enclosure class IP65, Nema 4X

Electrical safety class II

Pollution degree 2

Signal input

Max. load for level input 12 V, 5 mA

Max. load for pulse input 12 V, 5 mA

Max. load for external stop input 12 V, 5 mA

Min. pulse length [ms] 5

Max. pulse frequency [Hz] 100

Max. resistance in level/pulse circuit [Ω] 1000

Signal output

Max. ohmic load on relay output [A] 0.5

Max. voltage on relay output [V] 30 VDC/30 VAC

Weight/size

Weight (PVC, PP, PVDF) [kg] 2.4

Weight (stainless steel) [kg] 3.2

Diaphragm diameter [mm] 44 50

Sound pressure

Max. sound pressure level [dB(A)] 60

Approvals CE, CB, CSA-US, NSF61, EAC, ACS, RCM

Data 6-10 15-4

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3.2 Technical data for CIP (Clean-In-Place) applications

Short-term temperature limits for max. 40 minutes at max. 2 bar operating pressure:

3.3 Dimensions

The indicated dimensions are the same for all control variants of the DDE range. The following drawing shows the DDE-PR control variant.

Fig. 3 Dimensional sketch

Max. liquid temperature for dosing head material PVDF [°C] 85Max. liquid temperature for dosing head material stainless steel [°C] 120

The dosing head material Polyvinyl chloride (PVC) must not be used in CIP applications.

TM04

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7 31

17

110

4 x Ø6105

120

17.5

A1

B

C

161.

5

G 5/8

161D 17

Pump type A1 [mm] B [mm] C [mm] D [mm]

DDE 6-10 251 196 46.5 24

DDE 15-4 251 200.5 39.5 24

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4. Assembly and installation

4.1 Pump assembly

The pump is delivered with a mounting plate. The mounting plate can be mounted vertically, e.g. on a wall, or horizontally, e.g. on a tank. It takes just a few quick steps to firmly secure the pump to the mounting plate by means of a slot mechanism.The pump can easily be released from the mounting plate for maintenance.

4.1.1 Requirements

• The mounting surface must be stable and must not vibrate.

• Dosing must flow upwards vertically.

4.1.2 Align and install mounting plate

• Vertical installation: Mounting plate slot mechanism must be above.

• Horizontal installation: Mounting plate slot mechanism must be opposite the dosing head.

• The mounting plate can be used as a drill template, please see fig. 3 for drill hole distances.

Fig. 4 Locate mounting plate

1. Indicate drill holes.2. Drill holes.3. Secure mounting plate using four screws,

diameter 5 mm, to the wall, on the bracket or the tank.

4.1.3 Engage pump in mounting plate

1. Attach the pump to the mounting plate support clamps and slide under slight pressure until it engages.

Fig. 5 Engaging the pump

4.2 Hydraulic connection

Important information on installation

• Observe suction lift and hose diameter, see section 3.1 Technical data.

• Shorten hoses at right angles.• Ensure that there are no loops or kinks in the

hoses.• Keep suction line as short as possible.• Route suction line up towards the suction valve.• Installing a filter in the suction line protects the

entire installation against dirt and reduces the risk of leakage.

Note

For use in Australia:Installation of this product must comply with AS/NZS3500!Certificate of suitability number: CS9431RCM number: N20683

WarningInstall the pump in such a way that the plug can easily be reached by the operator during operation! This will enable the operator to separate the pump from the mains quickly in case of emergency!

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WarningMake sure that you do not damage any cables and lines during installation!

TM04

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9 01

10

WarningRisk of chemical burns!Wear protective clothing (gloves and goggles) when working on the dosing head, connections or lines!

Caution

The dosing head may contain water from the factory check!When dosing media which should not come into contact with water, another medium must be dosed beforehand!

CautionFaultless function can only be guaranteed in conjunction with lines supplied by Grundfos!

CautionThe lines used must comply with the pressure limits as per section 3.1 Technical data!

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Hose connection procedure

1. Push union nut and tensioning ring across hose.2. Push cone part fully into the hose, see fig. 6.3. Attach cone part with hose to the corresponding

pump valve.4. Tighten union nut manually.

– Do not use tools!5. Tighten up union nuts after 2-5 operating hours,

if using PTFE gaskets!6. Attach deaeration hose to the corresponding

connection (see fig. 2) and run into a container or a collecting tray.

Fig. 6 Hydraulic connection

Installation example

The pump offers various installation options. In the picture below, the pump is installed in conjunction with a suction line, level switch and multifunction valve on a Grundfos tank.

Fig. 7 Installation example

4.3 Electrical connection

Mains connection

The pump is supplied with assembled mains cable and plug.1. Set capacity adjustment knob to 0 %

(see 6.1 Operating elements).2. Connect the mains plug with the mains socket.

TM04

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NotePressure differential between suction and discharge side must be at least 1 bar/14.5 psi!

Caution

Tighten the dosing head screws with a torque wrench once before commissioning and again after 2-5 operating hours at 4 Nm.

TM04

817

1 35

10

Union nutTensioning ring

Cone part

Hose

Deaerationhose

Tank

Multifunction valve

Suction line with empty signal

WarningThe enclosure class (IP65/Nema 4X) is only guaranteed if plugs or protective caps are correctly installed!

WarningThe pump can start automatically when the mains voltage is switched on!Do not manipulate mains plug or cable!

Note

The mains plug is the separator separating the pump from the mains.The rated voltage of the pump, see section 2.4 Nameplate, must conform to local conditions.

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Signal connections

Applies to DDE-PR/P control variant.

Fig. 8 Wiring diagram of the electrical connections (DDE-PR/P)

External stop and pulse input

Level signals: empty and low-level signal

Relay outputs*

* applies to DDE-PR control variant

WarningElectric circuits of external devices connected to the pump inputs must be separated from dangerous voltage by means of double or reinforced insulation!

TM04

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11

13

42

3412

13

►2

1

GND

GND

12

3 4

34

1 2

12

3 4

FunctionPins

1/brown 2/white 3/blue 4/black

External stop GND XPulse GND X

FunctionPins

1 2 3 4

Low-level signal X GNDEmpty signal X GND

FunctionPins

1/brown 2/white 3/blue 4/black

Relay 1 (Alarm) X XRelay 2 (selectable) X X

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5. Startup

5.1 General notes

5.2 Check before commissioning

• Check that the rated voltage indicated on the nameplate complies with the local conditions.

• Check that all connections are assembled correctly. Tighten connections, if necessary.

• Check that the dosing head screws are tightened with the indicated torque (4 Nm). Tighten dosing head screws, if necessary.

• Check that all electrical cables and plugs are connected correctly.

5.3 Start and deaerate the pump

1. Connect mains supply (see 4.3 Electrical connection).

2. Open the deaeration valve by approximately half a turn.

3. DDE-PR/P control variant: Press the [100%] key and hold it down, until liquid flows out of the deaeration hose continuously and without any bubbles.

4. DDE-B control variant: Turn the capacity adjustment knob to 100 % and wait, until liquid flows out of the deaeration hose continuously and without any bubbles. Then set the capacity adjustment knob back to 0 %.

5. Close the deaeration valve.The pump is deaerated.

6. Operation

6.1 Operating elements

Fig. 9 Operating elements

* Applies to DDE-PR/P control variant.

Capacity adjustment knob

The capacity adjustment knob is used to set the capacity in percent of the maximum dosing flow of the pump. Due to the logarithmical increase of the percent values, even small dosing capacities can be set accurately.

Mechanical lock

The mechanical lock protects the set dosing capacity against unauthorised manipulation. For locking, tighten the screw until the adjustment knob cannot be turned anymore.

Keys and LEDs

When pressing and holding down the [100%] key, the pump doses at 100 % for a certain time. The [100%] key can be used e.g. for deaeration.The [Operation mode] key is used to change between the "Manual" and "Pulse" mode (see section 6.2.3 Change operation modes). According to the selected operation mode, the respective status LED is active ("Pulse" = LED above key; "Manual" = LED below key).

WarningSuction and discharge hoses must be connected correctly!The deaeration hose must be connected correctly and inserted into a suitable tank!

Caution

Tighten the dosing head screws with a torque wrench once before commissioning and again after 2-5 operating hours at 4 Nm.

TM04

115

0 31

17

NoteThe DDE-B control variant is only equipped with a status LED.

100%

100%0%

0.150.2

0.30.40.50.6

0.8

1.5 2 3 4 5 68

1520

304050

6080

101

Logarithmic scaleCapacity adjustment knob

Status LED "Manual"

Status LED "Pulse"*

[Operation mode] key*

Mechanical lock [100%] key*

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The status LEDs indicate the following operating statuses and faults:

* only DDE-PR/P control variant

6.2 Operation modes

Following operation modes are available:• Manual, see section 6.2.1 Manual

• Pulse*, see section 6.2.2 Pulse

* Applies to DDE-PR/P control variant.

6.2.1 Manual

In this operation mode, the pump doses constantly the dosing quantity set by the adjustment knob.The setting range depends on the pump type:

6.2.2 Pulse

Applies to DDE-PR/P control variant.

In this operation mode, the pump doses the set dosing volume for each incoming (potential-free) pulse, e.g. from a water meter. The pump automatically calculates the optimum stroke frequency for dosing the set volume per pulse.The calculation is based on:• the frequency of external pulses• the set stroke volume in percent.The dosing quantity per pulse is set to a value between 0.1 % and 100 % of the stroke volume using the adjustment knob.The setting range depends on the pump type:

The frequency of incoming pulses is multiplied by the set dosing volume. If the pump receives more pulses than it can process at the maximum dosing flow, it runs at the maximum stroke frequency in continuous operation. Excess pulses will be ignored.

6.2.3 Change operation modes

Applies to DDE-PR/P control variant.

1. Set adjustment knob to 0 %.2. Connect mains supply

(see section 4.3 Electrical connection).3. Hold down the [Operation mode] key for at least

5 seconds.The new operation mode is saved.

6.3 Inputs/outputs

Applies to DDE-PR/P control variant.

6.3.1 External stop

The pump can be stopped via an external contact, e.g. from a control room. When activating the external stop signal, the pump switches from the operating state "Running" into the operating state "Standby". According to the selected operation mode, the respective LED flashes red-green.

6.3.2 Empty and low-level signals

In order to monitor the filling level in the tank, a dual-level sensor can be connected to the pump. The pump responds to the signals as follows:

LED colour Pump status/fault

Green (flashing) stop

Green running

Red-green (flashing) standby (external stopped)*

Yellow low-level signal*

Red empty signal, pump stops*

Red (flashing) motor blocked, pump stops

Type Setting range [l/h]

DDE 6-10 0.0060 - 6

DDE 15-4 0.0150 - 15

Type Setting range [ml/pulse]

DDE 6-10 0.0008 - 0.81

DDE 15-4 0.0016 - 1.58

Sensor signal Pump status

Low level • LED lights up in yellow• Pump continues running

Empty • LED lights up in red• Pump stops

CautionWhen the tank is filled up again, the pump restarts automatically!

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6.3.3 Relay outputs

Applies to DDE-PR control variant.

The pump can switch two external signals using installed relays. The relays are switched by potential-free pulses. The connection diagram of the relays is shown in section 4.3 Electrical connection.Relay 1 is allocated with the alarm signals (tank empty, motor blocked) as standard. Relay 2 can be allocated with the following signals:

* Default setting

** The correct transmission of incoming pulses can only be guaranteed up to a pulse frequency of 5 Hz.

6.3.4 Change settings

The signal inputs (level signals, external stop) and the relay outputs are configured at the factory as normally open (NO) contacts. They can be re-configured as normally closed (NC) contacts. Relay 2 can be allocated with different signals.The activated settings are indicated by the status LEDs when the pump is in the setup mode. For entering the setup mode and changing settings, proceed as follows:1. Set adjustment knob to 0 %.2. Connect mains supply (see section 4.3 Electrical connection).3. Press [100%] key and [Operation mode] key simultaneously and hold them down for at least 5 seconds.

– The pump switches into setup mode 1. The active setup mode is indicated by the colour of the upper status LED. The current setting is indicated by the colour of the lower status LED.

4. Make the desired settings according to the following table:

* Only DDE-PR control variant

** Default setting

5.To exit setup mode, keep [100%] key and [Operation mode] key simultaneously pressed for at least 1 second.

Relay 2 signal Description

Low-level signal* low level in tank

Stroke signal each full stroke

Pulse input** each incoming pulse from pulse input

Switch setup modes with [Operation mode] key

Setup mode 1 Setup mode 2* Setup mode 3*

upper status LED Green Yellow Red

setup mode description

Contact type of signal inputs (low-level,

empty and external stop)

Contact type of relay outputs

Allocated signal of Relay 2

Change setting with [100%] key

low

er s

tatu

s LE

D Green NO** NO** Low-level signal**

Yellow NC NC stroke signal

Red - - pulse input

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7. ServiceIn order to ensure a long service life and dosing accuracy, wearing parts such as diaphragms and valves must be regularly checked for signs of wear. Where necessary, replace worn parts with original spare parts made from suitable materials.Should you have any questions, please contact your service partner.

7.1 Regular maintenance

* For media which result in increased wear, the service interval must be shortened.

7.2 Cleaning

If necessary, clean all pump surfaces with a dry and clean cloth.

7.3 Perform service

Only spare parts and accessories from Grundfos should be used for maintenance. The usage of non-original spare parts and accessories renders any liability for resulting damages null and void.Further information about carrying out maintenance can be found in the service kit catalogue on our homepage (www.grundfos.com).

7.3.1 Dosing head overview

Fig. 10 Dosing head, exploded view

WarningMaintenance work must only be carried out by qualified staff.

Interval Task

Daily

Check, if liquid leaks from the drain opening (fig. 10, pos. 11) and if the drain opening is blocked or soiled.If so, follow the instructions given in section 7.4 Diaphragm breakage.

Check, if liquid leaks from the dosing head or valves.If necessary, tighten dosing head screws with a torque wrench at 4 Nm.If necessary, tighten valves and cap nuts, or perform service (see 7.3 Perform service).

Weekly Clean all pump surfaces with a dry and clean cloth.

Every 3 months

Check dosing head screws.If necessary, tighten dosing head screws with a torque wrench at 4 Nm. Replace damaged screws immediately.

Every 2 years or 8000 operating hours*

Replace diaphragm and valves (see 7.3 Perform service)

WarningRisk of chemical burns!When dosing dangerous media, observe the corresponding precautions in the safety data sheets!Wear protective clothing (gloves and goggles) when working on the dosing head, connections or lines!Do not allow any chemicals to leak from the pump. Collect and dispose of all chemicals correctly!

CautionBefore any work to the pump, the pump must be disconnected from the power supply. The system must be pressureless!

TM04

112

3 21

10

1 Safety diaphragm

2 Flange

3 O-ring

4 Diaphragm

5 Valve on discharge side

6 Valve on suction side

7 Dosing head

8 Screws with discs

9 Cover

10 Deaeration valve

11 Drain opening

1 2 3 5 7 8

4 6 10

9

11

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7.3.2 Dismantling the diaphragm and valves

This section refers to fig. 10.1. Make system pressureless.2. Empty the dosing head before maintenance and

flush it, if necessary.3. Set adjustment knob to 0 %.4. Switch off mains supply.5. Take suitable steps to ensure that the returning

liquid is safely collected.6. Dismantle suction, pressure and deaeration

hoses.7. Dismantle valves on suction and discharge

side (5, 6).8. Remove the cover (9).9. Loosen screws (8) on the dosing head (7) and

remove the screws and discs.10. Remove the dosing head (7).11. Unscrew diaphragm (4) counter-clockwise and

remove with flange (2).12. Make sure the drain opening (11) is not blocked

or soiled. Clean if necessary.13. Check the safety diaphragm (1) for wear and

damage. Replace if necessary.If nothing indicates that dosing liquid has entered the pump housing, go on as described in section 7.3.3 Reassembling the diaphragm and valves. Otherwise proceed as described in section 7.4.2 Dosing liquid in the pump housing.

7.3.3 Reassembling the diaphragm and valves

The pump must only be reassembled, if nothing indicates that dosing liquid has entered the pump housing. Otherwise proceed as described in section 7.4.2 Dosing liquid in the pump housing.This section refers to fig. 10.1. Attach flange (2) correctly and screw on new

diaphragm (4) clockwise.– Make sure that the O-ring (3) is seated

correctly!2. Connect/switch on mains supply.3. Turn the adjustment knob slowly to bring the

diaphragm into its service position "inside" (end of suction phase, diaphragm retracted). Set adjustment knob back to 0 %.

4. Switch off mains supply again.5. Attach the dosing head (7).6. Install screws with discs (8) and cross-tighten

with a torque wrench.– Torque: 4 Nm.

7. Attach the cover (9).8. Install new valves (5, 6).

– Do not interchange valves and pay attention to direction of arrow.

9. Connect suction, pressure and deaeration hoses (see section 4.2 Hydraulic connection).

10. Deaerate dosing pump (see section 5.3 Start and deaerate the pump).

11. Please observe the notes on commissioning in section 5. Startup!

WarningDanger of explosion, if dosing liquid has entered the pump housing!If the diaphragm is possibly damaged, don’t connect the pump to the power supply! Proceed as described in section 7.4 Diaphragm breakage!

Caution

Tighten the dosing head screws with a torque wrench once before commissioning and again after 2-5 operating hours at 4 Nm.

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7.4 Diaphragm breakage

If the diaphragm leaks or is broken, dosing liquid escapes from the drain opening (fig. 10, pos. 11) on the dosing head.In case of diaphragm breakage, the safety diaphragm (fig. 10, pos. 1) protects the pump housing against ingress of dosing liquid.When dosing crystallising liquids the drain opening can be blocked by crystallisation. If the pump is not taken out of operation immediately, a pressure can build up between the diaphragm (fig. 10, pos. 4) and the safety diaphragm in the flange (fig. 10, pos. 2). The pressure can press dosing liquid through the safety diaphragm into the pump housing.Most dosing liquids don’t cause any danger when entering the pump housing. However a view liquids can cause a chemical reaction with inner parts of the pump. In the worst case, this reaction can produce explosive gases in the pump housing.

To avoid any danger resulting from diaphragm breakage, observe the following:• Perform regular maintenance. See section

7.1 Regular maintenance.• Never operate the pump with blocked or soiled

drain opening.– If the drain opening is blocked or soiled,

proceed as described in section 7.4.1 Dismantling in case of diaphragm breakage.

• Never attach a hose to the drain opening. If a hose is attached to the drain opening, it is impossible to recognise escaping dosing liquid.

• Take suitable precautions to prevent harm to health and damage to property from escaping dosing liquid.

• Never operate the pump with damaged or loose dosing head screws.

7.4.1 Dismantling in case of diaphragm breakage

This section refers to fig. 10.1. Make system pressureless.2. Empty dosing head before maintenance and

flush it if necessary.3. Take suitable steps to ensure that the returning

liquid is safely collected.4. Dismantle suction, pressure and deaeration

hose.5. Remove the cover (9).6. Loosen screws (8) on the dosing head (7) and

remove with discs.7. Remove the dosing head (7).8. Unscrew diaphragm (4) counter-clockwise and

remove with flange (2).9. Make sure the drain opening (11) is not blocked

or soiled. Clean if necessary.10. Check the safety diaphragm (1) for wear and

damage. Replace if necessary.If nothing indicates that dosing liquid has entered the pump housing, go on as described in section 7.3.3 Reassembling the diaphragm and valves. Otherwise proceed as described in section 7.4.2 Dosing liquid in the pump housing.

7.4.2 Dosing liquid in the pump housing

If dosing liquid has entered the pump housing:• Send the pump to Grundfos for repair, following

the instructions given in section 7.5 Repairs.• If a repair isn’t economically reasonable, dispose

of the pump observing the information in section 9. Disposal.

WarningDanger of explosion, if dosing liquid has entered the pump housing!Operation with damaged diaphragm can lead to dosing liquid entering the pump housing.In case of diaphragm breakage, immediately separate the pump from the power supply!Make sure the pump cannot be put back into operation by accident!Dismantle the dosing head without connecting the pump to the power supply and make sure no dosing liquid has entered the pump housing. Proceed as described in section 7.4.1 Dismantling in case of diaphragm breakage.

WarningDanger of explosion, if dosing liquid has entered the pump housing!Do not connect the pump to the power supply!

WarningDanger of explosion!Immediately separate the pump from the power supply!Make sure the pump cannot be put back into operation by accident!

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7.5 Repairs

After consulting Grundfos, please send the pump, together with the safety declaration completed by a specialist, to Grundfos. The safety declaration can be found at the end of these instructions. It must be copied, completed and attached to the pump.

If the above requirements are not met, Grundfos may refuse to accept delivery of the pump. The shipping costs will be charged to the sender.

8. Faults

8.1 Indication of faults

Depending on the selected operation mode, the pump indicates the following faults with its LEDs:

For further faults, please see 8.2 List of faults.

WarningThe pump housing must only be opened by personnel authorised by Grundfos!Repairs must only be carried out by authorised and qualified personnel!Switch off the pump and disconnect it from the voltage supply before carrying out maintenance work and repairs!

Caution

The pump must be cleaned prior to dispatch!If dosing liquid has possibly entered the pump housing, state that explicitly in the safety declaration! Observe section 7.4 Diaphragm breakage.

LED colour

Fault Remedy

Yellow low-level signal

• fill tank• check contact type

(see section 6.3.4).

Red empty signal• fill tank• check contact type

(see section 6.3.4).

Red (flashing)

motor blocked

• reduce backpressure

• have gear repaired, if necessary.

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8.2 List of faults

9. DisposalThis product or parts of it must be disposed of in an environmentally sound way. Use appropriate waste collection services.If this is not possible, contact the nearest Grundfos company or service workshop.

The crossed-out wheelie bin symbol on a product means that it must be disposed of separately from household waste. When a product marked with this symbol reaches its end of life, take it to a collection point designated by the local

waste disposal authorities. The separate collection and recycling of such products will help protect the environment and human health.See also end-of-life information at www.grundfos.com/product-recycling.

Fault Possible cause Possible remedy

Dosing flow too high Inlet pressure greater than backpressure

Install additional spring-loaded valve (approx. 3 bar) on the discharge side.

Increase pressure differential.

No dosing flow or dosing flow too low

Air in dosing head Deaerate the pump.

Faulty diaphragm Change the diaphragm (see section 7.3 Perform service).

Leakage/fracture in lines Check and repair lines.

Valves leaking or blocked Check and clean valves.

Valves installed incorrectlyCheck that the arrow on the valve housing is pointing in the direction of flow. Check whether all O-rings are installed correctly.

Blocked suction line Clean suction line/install filter.

Suction lift too highReduce suction lift.

Install priming aid.

Viscosity too highUse hose with larger diameter.

Install spring-loaded valve on the discharge side.

Deaeration valve open Close the deaeration valve.

Irregular dosingValves leaking or blocked Tighten up valves, replace valves if necessary

(see section 7.3 Perform service).

Backpressure fluctuations Keep backpressure constant.

Liquid escaping from the drain opening on the flange

Faulty diaphragm

Immediately separate the pump from the power supply!Observe section 7. Service and especially section 7.4 Diaphragm breakage.

Liquid escaping

Dosing head screws not tightened

Tighten up screws (see section 4.2 Hydraulic connection).

Valves not tightened Tighten up valves/union nuts(see section 4.2 Hydraulic connection).

Pump not sucking in

Suction lift too high Reduce suction lift; if necessary, provide positive inlet pressure.

Backpressure too high Open the deaeration valve.

Soiled valves Flush system, replace valves if necessary (see section 7.3 Perform service).

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Appendix 1

中国 RoHS

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ArgentinaBombas GRUNDFOS de Argentina S.A.Ruta Panamericana km. 37.500 Centro Industrial Garin1619 - Garin Pcia. de B.A.Phone: +54-3327 414 444Telefax: +54-3327 45 3190

AustraliaGRUNDFOS Pumps Pty. Ltd. P.O. Box 2040 Regency Park South Australia 5942 Phone: +61-8-8461-4611 Telefax: +61-8-8340 0155

AustriaGRUNDFOS Pumpen Vertrieb Ges.m.b.H.Grundfosstraße 2 A-5082 Grödig/Salzburg Tel.: +43-6246-883-0 Telefax: +43-6246-883-30

BelgiumN.V. GRUNDFOS Bellux S.A. Boomsesteenweg 81-83 B-2630 Aartselaar Tél.: +32-3-870 7300 Télécopie: +32-3-870 7301

BelarusПредставительство ГРУНДФОС в Минске 220125, Минск ул. Шафарнянская, 11, оф. 56, БЦ «Порт»Тел.: +375 17 397 397 3

+375 17 397 397 4Факс: +375 17 397 397 1E-mail: [email protected]

Bosnia and HerzegovinaGRUNDFOS SarajevoZmaja od Bosne 7-7A,BH-71000 SarajevoPhone: +387 33 592 480Telefax: +387 33 590 465www.ba.grundfos.come-mail: [email protected]

BrazilBOMBAS GRUNDFOS DO BRASILAv. Humberto de Alencar Castelo Branco, 630CEP 09850 - 300São Bernardo do Campo - SPPhone: +55-11 4393 5533Telefax: +55-11 4343 5015

BulgariaGrundfos Bulgaria EOODSlatina DistrictIztochna Tangenta street no. 100BG - 1592 SofiaTel. +359 2 49 22 200Fax. +359 2 49 22 201email: [email protected]

CanadaGRUNDFOS Canada Inc. 2941 Brighton Road Oakville, Ontario L6H 6C9 Phone: +1-905 829 9533 Telefax: +1-905 829 9512

ChinaGrundfos AlldosDosing & DisinfectionALLDOS (Shanghai) Water Technology Co. Ltd.West Unit, 1 Floor, No. 2 Building (T 4-2)278 Jinhu Road, Jin Qiao Export Processing ZonePudong New Area Shanghai, 201206Phone: +86 21 5055 1012Telefax: +86 21 5032 0596E-mail: [email protected]

ChinaGRUNDFOS Pumps (Shanghai) Co. Ltd.10F The Hub, No. 33 Suhong RoadMinhang DistrictShanghai 201106PRCPhone: +86-21 6122 5222 Telefax: +86-21 6122 5333

COLOMBIAGRUNDFOS Colombia S.A.S.Km 1.5 vía Siberia-Cota Conj. Potrero Chico,Parque Empresarial Arcos de Cota Bod. 1A.Cota, CundinamarcaPhone: +57(1)-2913444Telefax: +57(1)-8764586

CroatiaGRUNDFOS CROATIA d.o.o.Buzinski prilaz 38, BuzinHR-10010 ZagrebPhone: +385 1 6595 400 Telefax: +385 1 6595 499www.hr.grundfos.com

GRUNDFOS Sales Czechia and Slovakia s.r.o.Čapkovského 21779 00 OlomoucPhone: +420-585-716 111

DenmarkGRUNDFOS DK A/S Martin Bachs Vej 3 DK-8850 Bjerringbro Tlf.: +45-87 50 50 50 Telefax: +45-87 50 51 51 E-mail: [email protected]/DK

EstoniaGRUNDFOS Pumps Eesti OÜPeterburi tee 92G11415 TallinnTel: + 372 606 1690Fax: + 372 606 1691

FinlandOY GRUNDFOS Pumput AB Trukkikuja 1FI-01360 Vantaa Phone: +358-(0)207 889 500

FrancePompes GRUNDFOS Distribution S.A. Parc d’Activités de Chesnes 57, rue de Malacombe F-38290 St. Quentin Fallavier (Lyon) Tél.: +33-4 74 82 15 15 Télécopie: +33-4 74 94 10 51

GermanyGRUNDFOS Water Treatment GmbHReetzstraße 85D-76327 Pfinztal (Söllingen)Tel.: +49 7240 61-0 Telefax: +49 7240 61-177E-mail: [email protected]

GermanyGRUNDFOS GMBHSchlüterstr. 3340699 ErkrathTel.: +49-(0) 211 929 69-0 Telefax: +49-(0) 211 929 69-3799E-mail: [email protected] in Deutschland:E-mail: [email protected]

GreeceGRUNDFOS Hellas A.E.B.E. 20th km. Athinon-Markopoulou Av. P.O. Box 71 GR-19002 Peania Phone: +0030-210-66 83 400 Telefax: +0030-210-66 46 273

Hong KongGRUNDFOS Pumps (Hong Kong) Ltd. Unit 1, Ground floor Siu Wai Industrial Centre 29-33 Wing Hong Street & 68 King Lam Street, Cheung Sha Wan Kowloon Phone: +852-27861706 / 27861741 Telefax: +852-27858664

HungaryGRUNDFOS Hungária Kft.Tópark u. 8H-2045 Törökbálint, Phone: +36-23 511 110Telefax: +36-23 511 111

IndiaGRUNDFOS Pumps India Private Limited118 Old Mahabalipuram RoadThoraipakkamChennai 600 097Phone: +91-44 4596 6800

IndonesiaPT. GRUNDFOS POMPAGraha Intirub Lt. 2 & 3Jln. Cililitan Besar No.454. Makasar, Jakarta TimurID-Jakarta 13650Phone: +62 21-469-51900Telefax: +62 21-460 6910 / 460 6901

IrelandGRUNDFOS (Ireland) Ltd. Unit A, Merrywell Business ParkBallymount Road LowerDublin 12 Phone: +353-1-4089 800 Telefax: +353-1-4089 830

ItalyGRUNDFOS Pompe Italia S.r.l. Via Gran Sasso 4I-20060 Truccazzano (Milano)Tel.: +39-02-95838112 Telefax: +39-02-95309290 / 95838461

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Japan

GRUNDFOS Pumps K.K.1-2-3, Shin-Miyakoda, Kita-kuHamamatsu431-2103 JapanPhone: +81 53 428 4760Telefax: +81 53 428 5005

KoreaGRUNDFOS Pumps Korea Ltd.6th Floor, Aju Building 679-5Yeoksam-dong, Kangnam-ku, 135-916Seoul, KoreaPhone: +82-2-5317 600Telefax: +82-2-5633 725

LatviaSIA GRUNDFOS Pumps Latvia Deglava biznesa centrsAugusta Deglava ielā 60, LV-1035, Rīga,Tālr.: + 371 714 9640, 7 149 641Fakss: + 371 914 9646

LithuaniaGRUNDFOS Pumps UABSmolensko g. 6LT-03201 VilniusTel: + 370 52 395 430Fax: + 370 52 395 431

MalaysiaGRUNDFOS Pumps Sdn. Bhd.7 Jalan Peguam U1/25Glenmarie Industrial Park40150 Shah AlamSelangor Phone: +60-3-5569 2922Telefax: +60-3-5569 2866

MexicoBombas GRUNDFOS de México S.A. de C.V. Boulevard TLC No. 15Parque Industrial Stiva AeropuertoApodaca, N.L. 66600Phone: +52-81-8144 4000 Telefax: +52-81-8144 4010

NetherlandsGRUNDFOS NetherlandsVeluwezoom 351326 AE AlmerePostbus 22015 1302 CA ALMERE Tel.: +31-88-478 6336 Telefax: +31-88-478 6332 E-mail: [email protected]

New ZealandGRUNDFOS Pumps NZ Ltd.17 Beatrice Tinsley CrescentNorth Harbour Industrial EstateAlbany, AucklandPhone: +64-9-415 3240Telefax: +64-9-415 3250

NorwayGRUNDFOS Pumper A/S Strømsveien 344 Postboks 235, Leirdal N-1011 Oslo Tlf.: +47-22 90 47 00 Telefax: +47-22 32 21 50

PolandGRUNDFOS Pompy Sp. z o.o.ul. Klonowa 23Baranowo k. PoznaniaPL-62-081 PrzeźmierowoTel: (+48-61) 650 13 00Fax: (+48-61) 650 13 50

PortugalBombas GRUNDFOS Portugal, S.A. Rua Calvet de Magalhães, 241Apartado 1079P-2770-153 Paço de ArcosTel.: +351-21-440 76 00Telefax: +351-21-440 76 90

RomaniaGRUNDFOS Pompe România SRLBd. Biruintei, nr 103 Pantelimon county IlfovPhone: +40 21 200 4100Telefax: +40 21 200 4101E-mail: [email protected]

RussiaООО Грундфос Россияул. Школьная, 39-41Москва, RU-109544, Russia Тел. (+7) 495 564-88-00 (495) 737-30-00Факс (+7) 495 564 8811E-mail [email protected]

Serbia Grundfos Srbija d.o.o.Omladinskih brigada 90b11070 Novi Beograd Phone: +381 11 2258 740Telefax: +381 11 2281 769www.rs.grundfos.com

SingaporeGRUNDFOS (Singapore) Pte. Ltd. 25 Jalan Tukang Singapore 619264 Phone: +65-6681 9688 Telefax: +65-6681 9689

SlovakiaGRUNDFOS s.r.o.Prievozská 4D 821 09 BRATISLAVA Phona: +421 2 5020 1426sk.grundfos.com

SloveniaGRUNDFOS LJUBLJANA, d.o.o.Leskoškova 9e, 1122 LjubljanaPhone: +386 (0) 1 568 06 10Telefax: +386 (0)1 568 0619E-mail: [email protected]

South AfricaGrundfos (PTY) Ltd.16 Lascelles Drive, Meadowbrook Estate1609 Germiston, JohannesburgTel.: (+27) 10 248 6000Fax: (+27) 10 248 6002E-mail: [email protected]

SpainBombas GRUNDFOS España S.A. Camino de la Fuentecilla, s/n E-28110 Algete (Madrid) Tel.: +34-91-848 8800 Telefax: +34-91-628 0465

SwedenGRUNDFOS AB Box 333 (Lunnagårdsgatan 6) 431 24 Mölndal Tel.: +46 31 332 23 000Telefax: +46 31 331 94 60

SwitzerlandGRUNDFOS Pumpen AG Bruggacherstrasse 10 CH-8117 Fällanden/ZH Tel.: +41-44-806 8111 Telefax: +41-44-806 8115

TaiwanGRUNDFOS Pumps (Taiwan) Ltd. 7 Floor, 219 Min-Chuan Road Taichung, Taiwan, R.O.C. Phone: +886-4-2305 0868Telefax: +886-4-2305 0878

ThailandGRUNDFOS (Thailand) Ltd. 92 Chaloem Phrakiat Rama 9 Road,Dokmai, Pravej, Bangkok 10250Phone: +66-2-725 8999Telefax: +66-2-725 8998

TurkeyGRUNDFOS POMPA San. ve Tic. Ltd. Sti.Gebze Organize Sanayi Bölgesi Ihsan dede Caddesi,2. yol 200. Sokak No. 20441490 Gebze/ KocaeliPhone: +90 - 262-679 7979Telefax: +90 - 262-679 7905E-mail: [email protected]

UkraineБізнес Центр ЄвропаСтоличне шосе, 103м. Київ, 03131, Україна Телефон: (+38 044) 237 04 00 Факс.: (+38 044) 237 04 01E-mail: [email protected]

United Arab EmiratesGRUNDFOS Gulf DistributionP.O. Box 16768Jebel Ali Free ZoneDubaiPhone: +971-4- 8815 166Telefax: +971-4-8815 136

United KingdomGRUNDFOS Pumps Ltd. Grovebury Road Leighton Buzzard/Beds. LU7 4TL Phone: +44-1525-850000 Telefax: +44-1525-850011

U.S.A.GRUNDFOS Pumps Corporation 9300 Loiret Blvd.Lenexa, Kansas 66219Phone: +1-913-227-3400 Telefax: +1-913-227-3500

UzbekistanGrundfos Tashkent, Uzbekistan The Representative Office of Grundfos Kazakhstan in Uzbekistan 38a, Oybek street, Tashkent Телефон: (+998) 71 150 3290 / 71 150 3291Факс: (+998) 71 150 3292

Addresses revised 31.03.2020

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